US20110240365A1 - Internal Liquid Measurement and Monitoring System for a Three Phase Separator - Google Patents
Internal Liquid Measurement and Monitoring System for a Three Phase Separator Download PDFInfo
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- US20110240365A1 US20110240365A1 US13/077,921 US201113077921A US2011240365A1 US 20110240365 A1 US20110240365 A1 US 20110240365A1 US 201113077921 A US201113077921 A US 201113077921A US 2011240365 A1 US2011240365 A1 US 2011240365A1
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- 239000007788 liquid Substances 0.000 title claims abstract description 176
- 238000005259 measurement Methods 0.000 title claims abstract description 30
- 238000012544 monitoring process Methods 0.000 title claims abstract description 24
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 347
- 230000003068 static effect Effects 0.000 claims description 34
- 238000000034 method Methods 0.000 claims description 23
- 239000000853 adhesive Substances 0.000 claims description 12
- 230000001070 adhesive effect Effects 0.000 claims description 12
- 238000007689 inspection Methods 0.000 claims description 9
- 238000012546 transfer Methods 0.000 claims description 8
- 239000007789 gas Substances 0.000 description 14
- 238000012423 maintenance Methods 0.000 description 7
- 239000012530 fluid Substances 0.000 description 6
- 239000000203 mixture Substances 0.000 description 4
- 238000009434 installation Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000004891 communication Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000000149 penetrating effect Effects 0.000 description 2
- 238000010926 purge Methods 0.000 description 2
- 230000033228 biological regulation Effects 0.000 description 1
- 230000000740 bleeding effect Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 230000037452 priming Effects 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
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Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F15/00—Details of, or accessories for, apparatus of groups G01F1/00 - G01F13/00 insofar as such details or appliances are not adapted to particular types of such apparatus
- G01F15/08—Air or gas separators in combination with liquid meters; Liquid separators in combination with gas-meters
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F1/00—Measuring the volume flow or mass flow of fluid or fluent solid material wherein the fluid passes through a meter in a continuous flow
- G01F1/05—Measuring the volume flow or mass flow of fluid or fluent solid material wherein the fluid passes through a meter in a continuous flow by using mechanical effects
- G01F1/34—Measuring the volume flow or mass flow of fluid or fluent solid material wherein the fluid passes through a meter in a continuous flow by using mechanical effects by measuring pressure or differential pressure
- G01F1/36—Measuring the volume flow or mass flow of fluid or fluent solid material wherein the fluid passes through a meter in a continuous flow by using mechanical effects by measuring pressure or differential pressure the pressure or differential pressure being created by the use of flow constriction
- G01F1/40—Details of construction of the flow constriction devices
- G01F1/44—Venturi tubes
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F1/00—Measuring the volume flow or mass flow of fluid or fluent solid material wherein the fluid passes through a meter in a continuous flow
- G01F1/74—Devices for measuring flow of a fluid or flow of a fluent solid material in suspension in another fluid
Definitions
- the present invention generally relates to the measurement and monitoring of the oil and water produced from a three phase separator.
- the information provided by the present invention in addition to the traditional gas measurement system generates the three phase measurement results from well production.
- An inlet allows a mixture of fluids to enter a three phase separator.
- the mixture of fluids consists of two liquids and a gas.
- the gas is emptied out of the three phase separator by a gas outlet.
- a dump valve siphons a liquid, such as water or oil, out of the three phase separator by extending the siphon into the liquid with an extension fitting.
- the liquid is carried away from the three phase separator along a dump liquid line.
- tradition meters measure the volumetric flow rate of the liquid being carried along the dump liquid line.
- Differential pressure meters also known as head meters, are installed on the dump liquid lines outside of the three phase separator. Differential pressure meters experience problems with gas in the dump liquid lines because these meters are not completely submerged in the liquid being measured. Gas bubbles form in the sensing lines of these meters and create inaccurate readings. Differential pressure meters need to be continuously maintained by bleeding the gas bubbles from the sensing lines.
- Positive displacement meters have problems with installation, moving parts being damaged, accuracy, and reliability.
- Velocity meters undergo problems with installation, moving parts being damaged, accuracy, reliability, cost, conductivity of liquids, sensor coating, and noise interference.
- Mass meters experience problems with installation, cost, reliability, errors caused by gas pockets in the exiting liquids, noise interference, and intermittent slug errors.
- a pressure differential device such as a venturi tube is attached to the extension fitting, which submerges the pressure differential device in the liquid being measured.
- the sensing lines conveys the differential pressure to the sensor, which sends the measurement to an RTU flow computer.
- the RTU flow computer uses the pressure differential reading to calculate the volumetric flow rate of the liquid exiting the three phase separator.
- the RTU flow computer sends the volumetric flow rate calculation to a SCADA system, which records the calculation.
- the volumetric flow rate calculations are made in real time, and the SCADA system archives the calculations being made.
- This system has proven to be an accurate and reliable method to measure the volumetric flow rate through a dump valve, which allows operators to easily monitor and troubleshoot problems such as a leaking dump valve or a dump valve being stuck open.
- FIG. 1 illustrates the present invention in its entirety with the sensing lines exiting the three phase separator through the inspection plug hole.
- FIG. 2 also illustrates the present invention in its entirety but with the sensing lines exiting the three phase separator through the water extension fitting and the oil extension fitting.
- FIG. 3 is a magnified view of the water differential pressure device and the oil differential pressure device.
- FIG. 4 is a magnified view of the first sensor and the second sensor.
- FIG. 5 is an enlarged view of the replacement fitting.
- FIG. 6 is an enlarged view of the modified water extension fitting and the modified oil extension fitting.
- the present invention is an internal liquid measurement and monitoring system for a three separator.
- the three phase separator 1 is a cylindrical vessel that separates a mixture into its constitute fluids with a combination of pressure and gravity.
- a three phase separator 1 is used to separate a mixture that consists of gas 2 , liquid water 3 , and liquid oil 4 .
- a water dump valve 5 empties the liquid water 3 out of the three phase separator 1
- an oil dump valve 6 empties the liquid oil 4 out of the three phase separator 1 .
- the water dump valve 5 and the oil dump valve 6 are both siphon liquid dump valves and are located on the top of the three phase separator 1 .
- the water dump valve 5 empties the liquid water 3 out of the three phase separator 1 by penetrating the three phase separator 1 with a water extension fitting 7 , which attaches to the bottom of the water dump valve 5 .
- the oil dump valve 6 empties the liquid oil 4 out of the three phase separator 1 by penetrating the three phase separator 1 with an oil extension fitting 9 , which attaches to the bottom of the oil dump valve 6 .
- the water extension fitting 7 is a tube with a water dump valve body 8 and the oil extension fitting 9 is a tube with an oil dump valve body 10 , both of which extend the siphon of the water dump valve 5 and the siphon of the oil dump valve 6 into their respective liquids.
- the length of the water extension fitting 7 and the length of the oil extension fitting 9 are determined by the vertical location of the liquid water 3 and the liquid oil 4 in the three phase separator 1 .
- the method begins by creating a differential pressure in the liquid water 3 and the liquid oil 4 as the liquid water 3 and the liquid oil 4 flow out of the three phase separator 1 through the water dump valve 5 and the oil dump valve 6 .
- a water differential pressure device 11 is attached to the water extension fitting 7 .
- an oil differential pressure device 19 is attached the oil extension fitting 9 .
- the water differential pressure device 11 and the oil differential pressure device 19 are venturi tubes. The venturi tubes would allow the liquid water 3 and the liquid oil 4 to flow out of the three phase separator 1 relatively unrestricted.
- venturi tube remains accurate because it does not have any moving parts that require maintenance.
- the venturi tube can be sized to measure the volumetric flow rate of any fluid.
- Other embodiments of the water pressure differential device and the oil pressure differential device include orifices, conical orifice plates, quadrant edge, orifice plates, segmental wedges, integral wedges, flow tubes, flow nozzles, pilot tubes, elbow meters, target meters, and variable-area meters also known as rotameters.
- the water differential pressure device 11 comprises of a water inlet 12 , a high water pressure section 13 , a high water pressure tap 14 , a low water pressure section 15 , a low water pressure tap 16 , a water outlet 17 , and a first adhesive 18 .
- the water inlet 12 allows the liquid water 3 to enter the water differential pressure device 11 .
- the water inlet 12 leads the liquid water 3 into the high water pressure section 13 , which is followed by the low water pressure section 15 .
- the high water pressure tap 14 is positioned on high water pressure section 13
- the low water pressure tap 16 is positioned on the low water pressure section 15 .
- the water outlet 17 leads the liquid water 3 out of the water differential pressure device 11 and into the water extension fitting 7 , which is connected to the water outlet 17 by the first adhesive 18 .
- the oil differential pressure device 19 comprises of an oil inlet 20 , a high oil pressure section 21 , a high oil pressure tap 22 , a low oil pressure section 23 , a low oil pressure tap 24 , an oil outlet 25 , and a second adhesive 26 .
- the oil inlet 20 allows the liquid oil 4 to enter the oil differential pressure device 19 .
- the oil inlet 20 leads the liquid oil 4 into the high oil pressure section 21 , which is followed by the low oil pressure section 23 .
- the high oil pressure tap 22 is positioned on high oil pressure section 21
- the low oil pressure tap 24 is positioned on the low oil pressure section 23 .
- the oil outlet 25 leads the liquid oil 4 out of the oil differential pressure device 19 and into the oil extension fitting 9 , which is connected to the oil outlet 25 by the second adhesive 26 .
- the low water pressure section 15 and the low oil pressure section 23 have a smaller cross section than the high water pressure section 13 and the high oil pressure section 21 .
- the smaller cross section increases the line velocity of a fluid, which in turn decreases the static pressure of the fluid.
- the difference in pressure between the larger cross section and the smaller cross section is known as the differential pressure.
- a high water pressure sensing line 27 is attached to the high water pressure section 13
- a low water pressure sensing line 30 is attached to the low water pressure section 15 .
- the high water pressure sensing line 27 and the low water pressure sensing line 30 are tubes filled with liquid water 3 .
- the high water pressure sensing line 27 comprises of a high water pressure device end 28 and a high water pressure manifold end 29 .
- the high water pressure device end 28 is connected to the high water pressure tap 14 , which allows the liquid water 3 filling the high water pressure sensing line 27 to experience the higher static pressure.
- the low water pressure sensing line 30 comprises of a low water pressure device end 31 and a low water pressure manifold end 32 .
- the low water pressure device end 31 is connected to the low water pressure tap 16 , which allows the liquid water 3 filling the low water pressure sensing line 30 to experience the lower static pressure.
- the liquid water 3 within both the high water pressure sensing line 27 and the low water pressure sensing line 30 must be purged of all gas bubbles; otherwise the differential pressure of the liquid water 3 in the water differential pressure device 11 will not be the same as the differential pressure of the liquid water 3 within the high water pressure sensing line 27 and the low water pressure sensing line 30 .
- a high oil pressure sensing line 33 is attached to the high oil pressure section 21
- a low oil pressure sensing line 36 is attached to the low oil pressure section 23 .
- the high oil pressure sensing line 33 and the low oil pressure sensing line 36 are tubes filled with liquid oil 4 .
- the high oil pressure sensing line 33 comprises of a high oil pressure device end 34 and a high oil pressure manifold end 35 .
- the high oil pressure device end 34 is connected to the high oil pressure tap 22 , which allows the liquid oil 4 filling the high oil pressure sensing line 33 to experience the higher static pressure.
- the low oil pressure sensing line 36 comprises of a low oil pressure device end 37 and a low oil pressure manifold end 38 .
- the low oil pressure device end 37 is connected to the low oil pressure tap 24 , which allows the liquid oil 4 filling the low oil pressure sensing line 36 to experience the lower static pressure.
- the liquid oil 4 within both the high oil pressure sensing line 33 and the low oil pressure sensing line 36 must be purged of all gas bubbles; otherwise the differential pressure of the liquid oil 4 in the oil differential pressure device 19 will not be the same as the differential pressure of the liquid oil 4 within the high oil pressure sensing line 33 and the low oil pressure sensing line 36 .
- a plurality of shut-off valves 39 are located along the high water pressure sensing line 27 , the low water pressure sensing line 30 , the high oil pressure sensing line 33 , and the low oil pressure sensing line 36 . The plurality of shut-off valves 39 close the sensing lines to prevent any liquid water 3 or liquid oil 4 from escaping the three phase when the system needs to be isolated for maintenance or repairs.
- the high water pressure sensing line 27 and the low water pressure sensing line 30 must exit the three phase separator 1 before being able to connect to a first manifold 58 .
- the high oil pressure sensing line 33 and the low oil pressure sensing line 36 must exit the three phase separator 1 before being able to connect to a second manifold 62 .
- a three phase separator exit can be crafted by two different methods: an inspection plug hole method and an extension fitting method.
- the inspection plug hole method requires a replacement fitting 41 , which comprises of a high water pressure fitting hole 42 , a low water pressure fitting hole 43 , a high oil pressure fitting hole 44 , and a low oil pressure fitting hole 44 .
- the replacement fitting 41 is designed to replace an inspection plug which covers an inspection plug hole 40 on the three phase separator 1 .
- the high water pressure fitting hole 42 allows the high water pressure sensing line 27 to traverse through the replacement fitting 41 and connect to the first manifold 58 .
- the low water pressure fitting hole 43 allows the low water pressure sensing line 30 to traverse through the replacement fitting 41 and connect to the first manifold 58 .
- the high oil pressure fitting hole 44 allows the high oil pressure sensing line 33 to traverse through the replacement fitting 41 and connect to the second manifold 62 .
- the low oil pressure fitting hole 44 allows the low oil pressure sensing line 36 to traverse through the replacement fitting 41 and connect to the second manifold 62 .
- the replacement fitting 41 is hermetically sealed so that nothing but the high water pressure sensing line 27 , the low water pressure sensing line 30 , the high oil pressure sensing line 33 , and the low oil pressure sensing line 36 can pass through the inspection plug hole 40 and exit the three phase separator 1 .
- the extension fitting method requires custom modifications to the water extension fitting 7 and the oil extension fitting 9 .
- the additional components associated with the water extension fitting 7 include a high water pressure inside tube 46 , a high water pressure tunnel 47 , a high water pressure outside tube 48 , a low water pressure inside tube 49 , a low water pressure tunnel 50 , and a low water pressure outside tube 51 .
- Both the high water pressure tunnel 47 and the low water pressure tunnel 50 are holes drilled through the water dump valve body 8 and run parallel to the center axis of the water extension fitting 7 .
- the high water pressure inside tube 46 connects to the high water pressure tap 14 at one end and the high water pressure tunnel 47 at the other end.
- the high water pressure outside tube 48 engages the high water pressure tunnel 47 at one end and the first manifold 58 at the other end. Together, the high water pressure inside tube 46 , the high water pressure tunnel 47 , and the high water pressure outside tube 48 form the high water pressure sensing line 27 described above.
- the low water pressure inside tube 49 connects to the low water pressure tap 16 at one end and the low water pressure tunnel 50 at the other end.
- the low water pressure outside tube 51 engages the low water pressure tunnel 50 at one end and the first manifold 58 at the other end. Together, the low water pressure inside tube 49 , the low water pressure tunnel 50 , and the low water pressure outside tube 51 form the low water pressure sensing line 30 described above.
- the additional components associated with the oil extension fitting 9 include a high oil pressure inside tube 52 , a high oil pressure tunnel 53 , a high oil pressure outside tube 54 , a low oil pressure inside tube 55 , a low oil pressure tunnel 56 , and a low oil pressure outside tube 57 .
- Both the high oil pressure tunnel 53 and the low oil pressure tunnel 56 are holes drilled through the oil dump valve body 10 and run parallel to the center axis of the oil extension fitting 9 .
- the high oil pressure inside tube 52 connects to the high oil pressure tap 22 at one end and the high oil pressure tunnel 53 at the other end.
- the high oil pressure outside tube 54 engages the high oil pressure tunnel 53 at one end and the second manifold 62 at the other end.
- the high oil pressure inside tube 52 , the high oil pressure tunnel 53 , and the high oil pressure outside tube 54 form the high oil pressure sensing line 33 described above.
- the low oil pressure inside tube 55 connects to the low oil pressure tap 24 at one end and the low oil pressure tunnel 56 at the other end.
- the low oil pressure outside tube 57 engages the low oil pressure tunnel 56 at one end and the second manifold 62 at the other end.
- the low oil pressure inside tube 55 , the low oil pressure tunnel 56 , and the low oil pressure outside tube 57 form the low oil pressure sensing line 36 described above.
- the first manifold 58 connects the high water pressure sensing line 27 and the low water pressure sensing line 30 to a first sensor 59
- the second manifold 62 connects the high oil pressure sensing line 33 and low oil pressure sensing line 36 to a second sensor 63 .
- the first manifold 58 and the second manifold 62 are used for the maintenance of the present invention.
- the first manifold 58 can shut down and isolate either the high water pressure sensing line 27 or the low water pressure sensing line 30 .
- the first manifold 58 can also be used to purge any gas bubbles inside the high water pressure sensing line 27 and the low water pressure sensing line 30 .
- the second manifold 62 can shut down and isolate either the high oil pressure sensing line 33 or the low oil pressure sensing line 36 . Also, the second manifold 62 can be used to purge any gas bubbles from the high oil pressure sensing line 33 and the low oil pressure sensing line 36 .
- the first sensor 59 is used to convert the physical quantity of static pressure into a first electrical signal 60 .
- the first electrical signal 60 consists of a higher water static pressure reading, a lower water static pressure reading, and a water differential pressure reading, which is the difference between the static pressure of the liquid water 3 in the high water pressure sensing line 27 and the static pressure of the liquid water 3 in the low water pressure sensing line 30 .
- the second sensor 63 is used to convert the physical quantity of static pressure into a second electrical signal 64 .
- the second electrical signal 64 consists of a higher oil static pressure reading, a lower oil static pressure reading, and an oil differential pressure reading, which is the difference between the static pressure of the liquid oil 4 in the high oil pressure sensing line 33 and the static pressure of the liquid oil 4 in the low oil pressure sensing line 36 .
- Both the first sensor 59 and the second sensor 63 should be positioned below the lowest liquid level in the three phase separator 1 and positioned as close as possible to the water differential pressure device 11 and the oil differential pressure device 19 .
- the positioning of the first sensor 59 and the second sensor 63 keep the high water pressure sensing line 27 , the low water pressure sensing line 30 , the high oil pressure sensing line 33 , and low oil pressure sensing line 36 as short as possible, which reduces the gauge line error.
- the first sensor 59 and the second sensor 63 are differential multivariable transmitters capable of reading static pressure, differential pressure, and temperature.
- the static pressure, differential pressure, and temperature readings allow the user to calculate the production of a liquid in real time.
- Any brand of differential multivariable transmitter can be used as long as it meets the class 1, division 1, electrical safety regulations and meets the real time calculation requirements of the ISO (1991) and the ASME (1971).
- the RTU (Remote Terminal Unit) flow computer 69 translates the first electrical signal 60 and the second electrical signal 64 into digital values.
- the RTU flow computer 69 uses the digital value of the water differential pressure reading to calculate the volumetric flow rate of the liquid water 3 through the water dump valve 5 .
- the RTU flow computer 69 uses the digital value of the oil differential pressure reading to calculate the volumetric flow rate of the liquid oil 4 through the oil dump valve 6 .
- the equation for the volumetric flow rate depends on the design of the water differential pressure device 11 and the design of the oil differential pressure device 19 . In the preferred embodiment of the present invention, the volumetric flow rate through a venturi tube is
- the RTU flow computer 69 is connected to the first sensor 59 by a first electronic connection 61 and is connected to the second sensor 63 by the second electronic connection 65 .
- a temperature measuring device 66 is attached to the thermowell of the three phase separator 1 in order to obtain a water temperature reading and an oil temperature reading.
- the temperature measuring device 66 converts the water temperature reading and the oil temperature into a third electrical signal 67 .
- the temperature measuring device 66 sends the third electrical signal 67 along a third electronic connection 68 to the RTU flow computer 69 .
- the RTU flow computer 69 changes the third electrical signal 67 into a digital value for the water temperature and a digital value for the oil temperature.
- the temperature and pressure values are used to calculate the density changes in the liquid water 3 in real time and the density changes in the oil 4 in real time because the volumetric flow rate depends on the density of the flowing liquid.
- the temperature measuring device 66 is an RID (Resistive Thermal Device).
- the RTU flow computer 69 exchanges information with a SCADA (Supervisory control and data acquisition) system 71 by a data transfer connection 70 .
- the data transfer connection 70 is either a 232 communication link or a 485 communication link.
- the SCADA system 71 is an industrial computer control system used to monitor the three phase separator 1 .
- the startup procedure shall begin after all components have been properly installed and programmed to complete the real time liquid measurement calculations. All safety and maintenance procedures are important to follow in order to protect all personnel and the equipment involved in the method.
- the safety and maintenance procedures should include an isolation of the equipment procedure, a lock out or tag out procedure.
- the multivariable differential transmitters could be dry calibrated to their prospective full scale values for static pressure, differential pressure, and temperature ranges.
- the multivariable differential transmitters can be left out of the pressurized service until the liquid levels are properly set and the liquid levels remain balanced in the upper sight glass of the three phase separator 1 .
- Level control is accomplished by priming the three phase separator 1 so that the three phase separator 1 has a separate liquid water level and a separate liquid oil level in the control boxes.
- the float level controls are properly adjusted to maintain the liquid water level and the oil level.
- the multivariable differential transmitters can be pressurized and put into service after the liquid water level and the liquid oil level are set.
- the high water pressure sensing line 27 , the low water pressure sensing line 30 , the high oil pressure sensing line 33 , and the low oil pressure sensing line 36 must be purged of any gas bubbles so that the measurements are made only on the liquid water 3 and the liquid oil 4 . Any gases left in the sensing lines will cause measurement errors.
- the zero under pressure calibration is the last part of the safety and maintenance procedures.
- the multivariable differential transmitters must be in service with the sensing lines completely open and with the three phase separator 1 in a no flow condition.
- the three phase separator's downstream dump valve must be closed in a no leak condition.
- the multivariable differential transmitters are then calibrated to zero under pressure.
- the zero under pressure calibration has to be preformed to compensate for the head pressure difference between the sensing tubes and the differential pressure devices.
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Abstract
Description
- The current application claims a priority to the U.S. Provisional Patent application Ser. No. 61/319,517 filed on Mar. 31, 2010.
- The present invention generally relates to the measurement and monitoring of the oil and water produced from a three phase separator. The information provided by the present invention in addition to the traditional gas measurement system generates the three phase measurement results from well production.
- Traditional meters have had difficulties measuring the volumetric flow rate of liquids exiting a three phase separator. An inlet allows a mixture of fluids to enter a three phase separator. The mixture of fluids consists of two liquids and a gas. The gas is emptied out of the three phase separator by a gas outlet. A dump valve siphons a liquid, such as water or oil, out of the three phase separator by extending the siphon into the liquid with an extension fitting. The liquid is carried away from the three phase separator along a dump liquid line. Tradition meters measure the volumetric flow rate of the liquid being carried along the dump liquid line.
- Some traditional meters include differential pressure meters, positive displacement meters, velocity meters, and mass meters. Differential pressure meters, also known as head meters, are installed on the dump liquid lines outside of the three phase separator. Differential pressure meters experience problems with gas in the dump liquid lines because these meters are not completely submerged in the liquid being measured. Gas bubbles form in the sensing lines of these meters and create inaccurate readings. Differential pressure meters need to be continuously maintained by bleeding the gas bubbles from the sensing lines. Positive displacement meters have problems with installation, moving parts being damaged, accuracy, and reliability. Velocity meters undergo problems with installation, moving parts being damaged, accuracy, reliability, cost, conductivity of liquids, sensor coating, and noise interference. Mass meters experience problems with installation, cost, reliability, errors caused by gas pockets in the exiting liquids, noise interference, and intermittent slug errors.
- Problems with the traditional meters are solved by an internal liquid measurement and monitoring system. A pressure differential device such as a venturi tube is attached to the extension fitting, which submerges the pressure differential device in the liquid being measured. The sensing lines conveys the differential pressure to the sensor, which sends the measurement to an RTU flow computer. The RTU flow computer uses the pressure differential reading to calculate the volumetric flow rate of the liquid exiting the three phase separator. The RTU flow computer sends the volumetric flow rate calculation to a SCADA system, which records the calculation. The volumetric flow rate calculations are made in real time, and the SCADA system archives the calculations being made. This system has proven to be an accurate and reliable method to measure the volumetric flow rate through a dump valve, which allows operators to easily monitor and troubleshoot problems such as a leaking dump valve or a dump valve being stuck open.
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FIG. 1 illustrates the present invention in its entirety with the sensing lines exiting the three phase separator through the inspection plug hole. -
FIG. 2 also illustrates the present invention in its entirety but with the sensing lines exiting the three phase separator through the water extension fitting and the oil extension fitting. -
FIG. 3 is a magnified view of the water differential pressure device and the oil differential pressure device. -
FIG. 4 is a magnified view of the first sensor and the second sensor. -
FIG. 5 is an enlarged view of the replacement fitting. -
FIG. 6 is an enlarged view of the modified water extension fitting and the modified oil extension fitting. - All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.
- The present invention is an internal liquid measurement and monitoring system for a three separator. The three
phase separator 1 is a cylindrical vessel that separates a mixture into its constitute fluids with a combination of pressure and gravity. In petroleum engineering, a threephase separator 1 is used to separate a mixture that consists ofgas 2,liquid water 3, andliquid oil 4. Awater dump valve 5 empties theliquid water 3 out of the threephase separator 1, and anoil dump valve 6 empties theliquid oil 4 out of the threephase separator 1. Thewater dump valve 5 and theoil dump valve 6 are both siphon liquid dump valves and are located on the top of the threephase separator 1. Thewater dump valve 5 empties theliquid water 3 out of the threephase separator 1 by penetrating the threephase separator 1 with a water extension fitting 7, which attaches to the bottom of thewater dump valve 5. Theoil dump valve 6 empties theliquid oil 4 out of the threephase separator 1 by penetrating the threephase separator 1 with an oil extension fitting 9, which attaches to the bottom of theoil dump valve 6. The water extension fitting 7 is a tube with a waterdump valve body 8 and the oil extension fitting 9 is a tube with an oildump valve body 10, both of which extend the siphon of thewater dump valve 5 and the siphon of theoil dump valve 6 into their respective liquids. The length of the water extension fitting 7 and the length of the oil extension fitting 9 are determined by the vertical location of theliquid water 3 and theliquid oil 4 in the threephase separator 1. - The method begins by creating a differential pressure in the
liquid water 3 and theliquid oil 4 as theliquid water 3 and theliquid oil 4 flow out of the threephase separator 1 through thewater dump valve 5 and theoil dump valve 6. To create a differential pressure as theliquid water 3 production flows out of the threephase separator 1, a waterdifferential pressure device 11 is attached to the water extension fitting 7. Similarly, to create a differential pressure as theliquid oil 4 flows out of the threephase separator 1, an oildifferential pressure device 19 is attached the oil extension fitting 9. In the preferred embodiment of the present invention, the waterdifferential pressure device 11 and the oildifferential pressure device 19 are venturi tubes. The venturi tubes would allow theliquid water 3 and theliquid oil 4 to flow out of the threephase separator 1 relatively unrestricted. In addition, the venturi tube remains accurate because it does not have any moving parts that require maintenance. The venturi tube can be sized to measure the volumetric flow rate of any fluid. Other embodiments of the water pressure differential device and the oil pressure differential device include orifices, conical orifice plates, quadrant edge, orifice plates, segmental wedges, integral wedges, flow tubes, flow nozzles, pilot tubes, elbow meters, target meters, and variable-area meters also known as rotameters. - The water
differential pressure device 11 comprises of awater inlet 12, a highwater pressure section 13, a highwater pressure tap 14, a lowwater pressure section 15, a lowwater pressure tap 16, awater outlet 17, and afirst adhesive 18. Thewater inlet 12 allows theliquid water 3 to enter the waterdifferential pressure device 11. Thewater inlet 12 leads theliquid water 3 into the highwater pressure section 13, which is followed by the lowwater pressure section 15. The highwater pressure tap 14 is positioned on highwater pressure section 13, and the lowwater pressure tap 16 is positioned on the lowwater pressure section 15. Thewater outlet 17 leads theliquid water 3 out of the waterdifferential pressure device 11 and into the water extension fitting 7, which is connected to thewater outlet 17 by thefirst adhesive 18. Likewise, the oildifferential pressure device 19 comprises of anoil inlet 20, a highoil pressure section 21, a highoil pressure tap 22, a lowoil pressure section 23, a lowoil pressure tap 24, anoil outlet 25, and asecond adhesive 26. Theoil inlet 20 allows theliquid oil 4 to enter the oildifferential pressure device 19. Theoil inlet 20 leads theliquid oil 4 into the highoil pressure section 21, which is followed by the lowoil pressure section 23. The highoil pressure tap 22 is positioned on highoil pressure section 21, and the lowoil pressure tap 24 is positioned on the lowoil pressure section 23. Theoil outlet 25 leads theliquid oil 4 out of the oildifferential pressure device 19 and into the oil extension fitting 9, which is connected to theoil outlet 25 by thesecond adhesive 26. In both the waterdifferential pressure device 11 and the oildifferential pressure device 19, the lowwater pressure section 15 and the lowoil pressure section 23 have a smaller cross section than the highwater pressure section 13 and the highoil pressure section 21. The smaller cross section increases the line velocity of a fluid, which in turn decreases the static pressure of the fluid. The difference in pressure between the larger cross section and the smaller cross section is known as the differential pressure. - In order to detect the differential pressure of the
liquid water 3, a high waterpressure sensing line 27 is attached to the highwater pressure section 13, and a low waterpressure sensing line 30 is attached to the lowwater pressure section 15. The high waterpressure sensing line 27 and the low waterpressure sensing line 30 are tubes filled withliquid water 3. The high waterpressure sensing line 27 comprises of a high waterpressure device end 28 and a high water pressuremanifold end 29. The high waterpressure device end 28 is connected to the highwater pressure tap 14, which allows theliquid water 3 filling the high waterpressure sensing line 27 to experience the higher static pressure. The low waterpressure sensing line 30 comprises of a low waterpressure device end 31 and a low water pressure manifold end 32. The low waterpressure device end 31 is connected to the lowwater pressure tap 16, which allows theliquid water 3 filling the low waterpressure sensing line 30 to experience the lower static pressure. Theliquid water 3 within both the high waterpressure sensing line 27 and the low waterpressure sensing line 30 must be purged of all gas bubbles; otherwise the differential pressure of theliquid water 3 in the waterdifferential pressure device 11 will not be the same as the differential pressure of theliquid water 3 within the high waterpressure sensing line 27 and the low waterpressure sensing line 30. - Similarly, in order to detect the differential pressure of the
liquid oil 4, a high oilpressure sensing line 33 is attached to the highoil pressure section 21, and a low oilpressure sensing line 36 is attached to the lowoil pressure section 23. The high oilpressure sensing line 33 and the low oilpressure sensing line 36 are tubes filled withliquid oil 4. The high oilpressure sensing line 33 comprises of a high oilpressure device end 34 and a high oil pressuremanifold end 35. The high oilpressure device end 34 is connected to the highoil pressure tap 22, which allows theliquid oil 4 filling the high oilpressure sensing line 33 to experience the higher static pressure. The low oilpressure sensing line 36 comprises of a low oilpressure device end 37 and a low oil pressuremanifold end 38. The low oilpressure device end 37 is connected to the lowoil pressure tap 24, which allows theliquid oil 4 filling the low oilpressure sensing line 36 to experience the lower static pressure. Theliquid oil 4 within both the high oilpressure sensing line 33 and the low oilpressure sensing line 36 must be purged of all gas bubbles; otherwise the differential pressure of theliquid oil 4 in the oildifferential pressure device 19 will not be the same as the differential pressure of theliquid oil 4 within the high oilpressure sensing line 33 and the low oilpressure sensing line 36. In addition, a plurality of shut-offvalves 39 are located along the high waterpressure sensing line 27, the low waterpressure sensing line 30, the high oilpressure sensing line 33, and the low oilpressure sensing line 36. The plurality of shut-offvalves 39 close the sensing lines to prevent anyliquid water 3 orliquid oil 4 from escaping the three phase when the system needs to be isolated for maintenance or repairs. - The high water
pressure sensing line 27 and the low waterpressure sensing line 30 must exit the threephase separator 1 before being able to connect to afirst manifold 58. Likewise, the high oilpressure sensing line 33 and the low oilpressure sensing line 36 must exit the threephase separator 1 before being able to connect to asecond manifold 62. A three phase separator exit can be crafted by two different methods: an inspection plug hole method and an extension fitting method. The inspection plug hole method requires a replacement fitting 41, which comprises of a high water pressure fitting hole 42, a low waterpressure fitting hole 43, a high oilpressure fitting hole 44, and a low oilpressure fitting hole 44. The replacement fitting 41 is designed to replace an inspection plug which covers aninspection plug hole 40 on the threephase separator 1. The high water pressure fitting hole 42 allows the high waterpressure sensing line 27 to traverse through the replacement fitting 41 and connect to thefirst manifold 58. The low waterpressure fitting hole 43 allows the low waterpressure sensing line 30 to traverse through the replacement fitting 41 and connect to thefirst manifold 58. The high oilpressure fitting hole 44 allows the high oilpressure sensing line 33 to traverse through the replacement fitting 41 and connect to thesecond manifold 62. The low oilpressure fitting hole 44 allows the low oilpressure sensing line 36 to traverse through the replacement fitting 41 and connect to thesecond manifold 62. The replacement fitting 41 is hermetically sealed so that nothing but the high waterpressure sensing line 27, the low waterpressure sensing line 30, the high oilpressure sensing line 33, and the low oilpressure sensing line 36 can pass through theinspection plug hole 40 and exit the threephase separator 1. - The extension fitting method requires custom modifications to the water extension fitting 7 and the oil extension fitting 9. For this method, the additional components associated with the water extension fitting 7 include a high water pressure inside
tube 46, a highwater pressure tunnel 47, a high water pressure outsidetube 48, a low water pressure insidetube 49, a lowwater pressure tunnel 50, and a low water pressure outsidetube 51. Both the highwater pressure tunnel 47 and the lowwater pressure tunnel 50 are holes drilled through the waterdump valve body 8 and run parallel to the center axis of the water extension fitting 7. The high water pressure insidetube 46 connects to the highwater pressure tap 14 at one end and the highwater pressure tunnel 47 at the other end. The high water pressure outsidetube 48 engages the highwater pressure tunnel 47 at one end and thefirst manifold 58 at the other end. Together, the high water pressure insidetube 46, the highwater pressure tunnel 47, and the high water pressure outsidetube 48 form the high waterpressure sensing line 27 described above. Likewise, the low water pressure insidetube 49 connects to the lowwater pressure tap 16 at one end and the lowwater pressure tunnel 50 at the other end. The low water pressure outsidetube 51 engages the lowwater pressure tunnel 50 at one end and thefirst manifold 58 at the other end. Together, the low water pressure insidetube 49, the lowwater pressure tunnel 50, and the low water pressure outsidetube 51 form the low waterpressure sensing line 30 described above. - Also for the extension fitting method, the additional components associated with the oil extension fitting 9 include a high oil pressure inside
tube 52, a highoil pressure tunnel 53, a high oil pressure outsidetube 54, a low oil pressure insidetube 55, a lowoil pressure tunnel 56, and a low oil pressure outsidetube 57. Both the highoil pressure tunnel 53 and the lowoil pressure tunnel 56 are holes drilled through the oildump valve body 10 and run parallel to the center axis of the oil extension fitting 9. The high oil pressure insidetube 52 connects to the highoil pressure tap 22 at one end and the highoil pressure tunnel 53 at the other end. The high oil pressure outsidetube 54 engages the highoil pressure tunnel 53 at one end and thesecond manifold 62 at the other end. Together, the high oil pressure insidetube 52, the highoil pressure tunnel 53, and the high oil pressure outsidetube 54 form the high oilpressure sensing line 33 described above. Similarly, the low oil pressure insidetube 55 connects to the lowoil pressure tap 24 at one end and the lowoil pressure tunnel 56 at the other end. The low oil pressure outsidetube 57 engages the lowoil pressure tunnel 56 at one end and thesecond manifold 62 at the other end. Together, the low oil pressure insidetube 55, the lowoil pressure tunnel 56, and the low oil pressure outsidetube 57 form the low oilpressure sensing line 36 described above. - The
first manifold 58 connects the high waterpressure sensing line 27 and the low waterpressure sensing line 30 to afirst sensor 59, and thesecond manifold 62 connects the high oilpressure sensing line 33 and low oilpressure sensing line 36 to asecond sensor 63. Thefirst manifold 58 and thesecond manifold 62 are used for the maintenance of the present invention. Thefirst manifold 58 can shut down and isolate either the high waterpressure sensing line 27 or the low waterpressure sensing line 30. Thefirst manifold 58 can also be used to purge any gas bubbles inside the high waterpressure sensing line 27 and the low waterpressure sensing line 30. Similarly, thesecond manifold 62 can shut down and isolate either the high oilpressure sensing line 33 or the low oilpressure sensing line 36. Also, thesecond manifold 62 can be used to purge any gas bubbles from the high oilpressure sensing line 33 and the low oilpressure sensing line 36. - The
first sensor 59 is used to convert the physical quantity of static pressure into a firstelectrical signal 60. The firstelectrical signal 60 consists of a higher water static pressure reading, a lower water static pressure reading, and a water differential pressure reading, which is the difference between the static pressure of theliquid water 3 in the high waterpressure sensing line 27 and the static pressure of theliquid water 3 in the low waterpressure sensing line 30. Likewise, thesecond sensor 63 is used to convert the physical quantity of static pressure into a secondelectrical signal 64. The secondelectrical signal 64 consists of a higher oil static pressure reading, a lower oil static pressure reading, and an oil differential pressure reading, which is the difference between the static pressure of theliquid oil 4 in the high oilpressure sensing line 33 and the static pressure of theliquid oil 4 in the low oilpressure sensing line 36. Both thefirst sensor 59 and thesecond sensor 63 should be positioned below the lowest liquid level in the threephase separator 1 and positioned as close as possible to the waterdifferential pressure device 11 and the oildifferential pressure device 19. The positioning of thefirst sensor 59 and thesecond sensor 63 keep the high waterpressure sensing line 27, the low waterpressure sensing line 30, the high oilpressure sensing line 33, and low oilpressure sensing line 36 as short as possible, which reduces the gauge line error. In the preferred embodiment, thefirst sensor 59 and thesecond sensor 63 are differential multivariable transmitters capable of reading static pressure, differential pressure, and temperature. The static pressure, differential pressure, and temperature readings allow the user to calculate the production of a liquid in real time. Any brand of differential multivariable transmitter can be used as long as it meets theclass 1,division 1, electrical safety regulations and meets the real time calculation requirements of the ISO (1991) and the ASME (1971). - The RTU (Remote Terminal Unit) flow
computer 69 translates the firstelectrical signal 60 and the secondelectrical signal 64 into digital values. TheRTU flow computer 69 uses the digital value of the water differential pressure reading to calculate the volumetric flow rate of theliquid water 3 through thewater dump valve 5. Similarly, theRTU flow computer 69 uses the digital value of the oil differential pressure reading to calculate the volumetric flow rate of theliquid oil 4 through theoil dump valve 6. The equation for the volumetric flow rate depends on the design of the waterdifferential pressure device 11 and the design of the oildifferential pressure device 19. In the preferred embodiment of the present invention, the volumetric flow rate through a venturi tube is -
- where Qv is the volumetric flow rate, Athroat is the cross-sectional area of the low pressure section, Δp is differential pressure, ρ is the flowing density of the liquid, and β is the ratio between the diameter of the low pressure section and the diameter of the high pressure section. The
RTU flow computer 69 is connected to thefirst sensor 59 by a firstelectronic connection 61 and is connected to thesecond sensor 63 by the secondelectronic connection 65. - In addition to the
first sensor 59 and thesecond sensor 63, atemperature measuring device 66 is attached to the thermowell of the threephase separator 1 in order to obtain a water temperature reading and an oil temperature reading. Thetemperature measuring device 66 converts the water temperature reading and the oil temperature into a thirdelectrical signal 67. Thetemperature measuring device 66 sends the thirdelectrical signal 67 along a thirdelectronic connection 68 to theRTU flow computer 69. TheRTU flow computer 69 changes the thirdelectrical signal 67 into a digital value for the water temperature and a digital value for the oil temperature. The temperature and pressure values are used to calculate the density changes in theliquid water 3 in real time and the density changes in theoil 4 in real time because the volumetric flow rate depends on the density of the flowing liquid. In the preferred embodiment, thetemperature measuring device 66 is an RID (Resistive Thermal Device). - Finally, the
RTU flow computer 69 exchanges information with a SCADA (Supervisory control and data acquisition)system 71 by adata transfer connection 70. In the preferred embodiment, thedata transfer connection 70 is either a 232 communication link or a 485 communication link. TheSCADA system 71 is an industrial computer control system used to monitor the threephase separator 1. - For the maintenance of the present invention, the startup procedure shall begin after all components have been properly installed and programmed to complete the real time liquid measurement calculations. All safety and maintenance procedures are important to follow in order to protect all personnel and the equipment involved in the method. The safety and maintenance procedures should include an isolation of the equipment procedure, a lock out or tag out procedure.
- In the preferred embodiment, the multivariable differential transmitters could be dry calibrated to their prospective full scale values for static pressure, differential pressure, and temperature ranges. The multivariable differential transmitters can be left out of the pressurized service until the liquid levels are properly set and the liquid levels remain balanced in the upper sight glass of the three
phase separator 1. - Level control is accomplished by priming the three
phase separator 1 so that the threephase separator 1 has a separate liquid water level and a separate liquid oil level in the control boxes. The float level controls are properly adjusted to maintain the liquid water level and the oil level. The multivariable differential transmitters can be pressurized and put into service after the liquid water level and the liquid oil level are set. - The high water
pressure sensing line 27, the low waterpressure sensing line 30, the high oilpressure sensing line 33, and the low oilpressure sensing line 36 must be purged of any gas bubbles so that the measurements are made only on theliquid water 3 and theliquid oil 4. Any gases left in the sensing lines will cause measurement errors. - The zero under pressure calibration is the last part of the safety and maintenance procedures. The multivariable differential transmitters must be in service with the sensing lines completely open and with the three
phase separator 1 in a no flow condition. The three phase separator's downstream dump valve must be closed in a no leak condition. The multivariable differential transmitters are then calibrated to zero under pressure. The zero under pressure calibration has to be preformed to compensate for the head pressure difference between the sensing tubes and the differential pressure devices. - Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.
Claims (19)
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US31951710P | 2010-03-31 | 2010-03-31 | |
US13/077,921 US8707779B2 (en) | 2010-03-31 | 2011-03-31 | Internal liquid measurement and monitoring system for a three phase separator |
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